CN108453642B

CN108453642B - Tool assembly for use with a panel and method of supporting a panel by means of a tool assembly

Info

Publication number: CN108453642B
Application number: CN201810051335.4A
Authority: CN
Inventors: 杰弗里·H·奥尔伯格; 丹尼尔·J·佩龙; 沙恩·E·阿瑟
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2017-02-20
Filing date: 2018-01-18
Publication date: 2021-08-13
Anticipated expiration: 2038-01-18
Also published as: EP3363588A1; CN108453642A; EP3363588B1

Abstract

A tool assembly for use with a panel defining a tool side surface and a method for supporting the panel by the tool assembly are provided, and the tool side surface defines a profile. The tool assembly includes a base, a plurality of support members fixedly attached to the base, a plurality of frames, and a securing system. The frames each define an upper surface, wherein each support member is releasably coupled to the corresponding frame by a fastening system. The upper surfaces of the frames are each shaped to correspond to a portion of the profile of the tool-side surface of the panel. The securing system is for providing a suction force configured to releasably secure the panel against the upper surface of the frame.

Description

Tool assembly for use with a panel and method of supporting a panel by means of a tool assembly

Technical Field

Embodiments of the subject matter described herein relate generally to a tool holder, and in particular to a tool holder that includes a plurality of frames releasably coupled to a base of the tool holder and a faceplate releasably coupled to the frames.

Background

Various parts such as, for example, aircraft panels, may be manufactured using tools. Conventional tools typically include a tool support or frame and a face plate defining a tool surface, wherein the face plate is integral with the support. The tool may be used to manufacture a variety of parts. For example, composite structures may be manufactured by placing a composite material along a tool surface, and then applying a vacuum to hold the composite material during curing.

While conventional tools are widely used to manufacture various parts, several challenges currently exist. For example, conventional tools are typically heavy and bulky. Thus, a large amount of capital equipment is required to move the tools within the facility. Moreover, since tools are typically bulky, they typically occupy a large amount of space within the facility. Since conventional tools are typically only capable of manufacturing a single part, multiple tools are often stacked within a storage area of a facility. This can cause problems, especially if the facility has only limited storage space. Finally, many conventional tools can be difficult and expensive to repair or modify. In particular, if a component is subjected to design changes in the event of a change in the shape or form of the component, the tool may need to undergo extensive rework in order to accommodate the design change.

Disclosure of Invention

In one embodiment, a tool assembly is provided for use with a face plate defining a tool side surface, and the tool side surface defines a profile. The tool assembly includes a base, a plurality of support members fixedly attached to the base, a plurality of frames, and a securing system. The frames each define an upper surface, wherein each support member is releasably coupled to the corresponding frame by a fastening system. The upper surfaces of the frames are each shaped to correspond to a portion of the profile of the tool-side surface of the panel. The securing system is for providing a suction force configured to releasably secure the panel against the upper surface of the frame.

In another embodiment, a tool assembly for use with a face plate defining a tool side surface is provided and the tool side surface defines a profile. The tool assembly includes a base, a plurality of support members fixedly attached to the base, a plurality of frames, a securing system, and a rotation assembly. The frames each define an upper surface, wherein each support member is releasably coupled to the corresponding frame by a fastening system. The upper surfaces of the frames are each shaped to correspond to a portion of the profile of the tool-side surface of the panel. The securing system is for providing a suction force configured to releasably secure the panel against the upper surface of the frame. The rotating assembly includes a shaft, wherein the shaft is rotatably connected to the base.

In another embodiment, a method for supporting a panel with a tool assembly is disclosed. The method includes fixedly attaching a plurality of support members to a substrate. The method also includes releasably coupling each of the support members to a corresponding one of the plurality of frames with a fastening system, wherein the frames each define a corresponding upper surface. The method also includes releasably coupling the panel to the frame by providing a suction force by the securing system.

Other objects and advantages of the disclosed method and system will be apparent from the following description, the accompanying drawings and the appended claims.

Drawings

FIG. 1 is a perspective view of a disclosed modular tool assembly, wherein the modular tool assembly includes a base, a plurality of frames, and a face plate;

FIG. 2 is an illustration of the tool assembly shown in FIG. 1 with the faceplate removed to expose a plurality of vacuum cups for securing the faceplate to the frame;

FIG. 3 is an exploded view of the tool assembly shown in FIG. 1;

FIG. 4 is an enlarged view of the rotation assembly of the tool assembly shown in FIG. 1;

FIG. 5 is another view of the rotating assembly shown in FIG. 4;

FIG. 6 is an illustration of an alternative embodiment of the disclosed tool assembly including a manifold system for securing a faceplate to a frame;

FIG. 7 is a perspective view of the tool assembly shown in FIG. 6;

FIG. 8 shows a valve connected to one of the frames of the tool assembly;

FIG. 9 is a cross-sectional view of the frame shown in FIG. 8; and

FIG. 10 is an exemplary process flow diagram illustrating a method for supporting a panel using the disclosed tool assembly.

Detailed Description

The tool holders or assemblies described herein are relatively quickly reconfigured to support panels having different profiles. More specifically, the tool assembly may be used with multiple sets of frames, where each set of frames corresponds to a particular profile of the panel. By changing the set of frames coupled to the tool assembly, the tool assembly can be reconfigured for a different panel. For example, when a new part is to be processed, the current set of frames is removed from the tool assembly and the new set of frames is coupled to the supports of the tool assembly. The frames are slidable along the supports to adjust the position of each frame to define a predetermined profile corresponding to the part. In addition, a different number of frames may be used depending on the parts. For example, a frame may be added to provide additional strength to support the part. For shorter parts, the frames may be removed and/or positioned closer together.

Referring now to FIG. 1, an exemplary modular tool holder or assembly 10 is shown. The tool assembly 10 includes a base 20, a plurality of frames 22 (see fig. 2), and a plurality of support members 28. The tool assembly 10 may be used with a test specimen or panel 24. The face plate 24 defines a tool surface 26 for forming a pattern or mold. As explained in more detail below, the frames 22 are each releasably coupled to one of the support members 28 of the tool assembly 10, and the faceplate 24 is releasably coupled to the frame 22. In the exemplary embodiment shown, the tool surface 26 of the panel 24 includes a contour or profile that is arcuate or curved when viewed along one of the sides 30 of the panel 24. However, the profile of the tool surface 26 varies to suit a particular application.

Turning now to fig. 2, the panel 24 has been removed to reveal a plurality of frames 22 and a securing system 38, shown as a plurality of vacuum cups 36. The securing system 38 is configured to provide a suction force that releasably secures the panel 24 against the upper surface 34 of the frame 22. Although fig. 2 shows a total of nine frames 22, this embodiment is merely exemplary in nature. In one embodiment, the number of frames 22 depends on the length 37 (FIG. 1) of the panel 24. For example, if the length 37 of the panel 24 is increased, additional frames 22 may be included to provide additional support and strength. Similarly, if the length 37 of the panel 24 is shortened, fewer frames 22 may be required in another approach.

Referring to fig. 1 and 2, the frames 22 each define a corresponding upper surface 34. The face plate 24 defines a tool side surface 32. The tool side surface 32 defines a contour that may correspond to the contour of the tool surface 26 of the face plate 24. The upper surfaces 34 of the frames 22 are each shaped to correspond to a portion of the contour defined by the tool side surface 32 of the face plate 24. In the embodiment shown in FIG. 1, the tool side surface 32 of the face plate 24 includes a curved profile. However, this profile is merely exemplary in nature. In another embodiment, the tool side surface 32 of the face plate 24 may also include a planar or flat profile. The tool side surface 32 abuts or seats against an upper surface 34 of each frame 22. The vacuum cups 36 of the securing system 38 provide a suction force configured to releasably couple the panels 24 against the upper surface 34 of the frame 22. The amount of suction applied by the vacuum cup 36 is based at least in part on the thickness of the panel 24 and is explained in detail below. Further, although a vacuum cup 36 is shown in fig. 2, the securing system 38 may include any other vacuum device capable of providing the suction required to releasably couple the panel 24 to the frame 22. For example, in an alternative embodiment shown in fig. 6 and described in detail below, the fixation system 38 includes a plurality of manifolds 200.

Returning to fig. 1 and 2, the base 20 of the tool assembly 10 may be supported by a plurality of flywheels or wheels 40. The wheel 40 may be attached to a bottom portion 42 of the base 20. The wheels 40 support a pair of rods 50 of the base 20. The rods 50 may be disposed at the opposite side 44 of the tool assembly 10. In the illustrated embodiment, the rods 50 are both oriented substantially parallel to each other. Turning now to fig. 3, which is an exploded view of the tool assembly 10, the rods 50 may each support a corresponding leg 52 of the tool assembly 10. Specifically, each leg 52 may be comprised of two panels 46 and a support 48. Two panels 46 may be attached to a support 48, with the panels 46 generally opposing each other.

Each leg 52 may further define a first end portion 54 and a second end portion 56. The first end portions 54 of the legs 52 may define elongated portions 58. The elongate portion 58 of each leg 52 may extend in a direction substantially transverse to the leg 52 and be secured to a corresponding one of the side bars 50. The second end portions 56 of the legs 52 may be connected to one of two swivel assemblies 60.

Referring now to fig. 4, the second end portion 56 of each leg 52 defines an aperture 62. The bore 62 is shaped to receive a shaft 64. The shaft 64 defines an axis of rotation a and is rotatably connected to the base 20 of the tool assembly 10. The tool assembly 10 also includes a pillow block bearing 68. The pillow block bearings 68 comprise anti-friction bearings (not visible in fig. 4) and a housing 66, wherein the anti-friction bearings are housed within the housing 66. The shaft 64 is received within the anti-friction bearings of the pillow block bearings 68 and rotates about its axis of rotation a within the anti-friction bearings of the pillow block bearings 68. As shown in fig. 4, the pillow block bearing 68 is mounted on a lower surface 71 of a support rod 70 of the base 20. The pillow block bearing 68 is also referred to as a housed bearing unit or thrust bearing, and is any type of mountable bearing in which the mounted shaft (i.e., the shaft 64) is positioned in a substantially parallel plane relative to a mounting surface (i.e., the mounting surface 69) of the pillow block bearing 68.

Referring to fig. 3 and 4, the base 20 includes two support rods 70. Each support bar 70 may be positioned at one of the sides 44 of the base 20. The base 20 may also include two elongated rods 72 oriented in a direction substantially parallel to each other and substantially perpendicular with respect to the support rods 70. As shown in fig. 3, a plurality of rods 74 are mounted along the two rods 72. The rods 74 are oriented in a direction substantially perpendicular to the two rods 72 and are spaced apart from each other by substantially equal distances. In addition, the rods 74 are arranged along the entire length L of the two rods 72. However, the embodiment as shown in fig. 3 and 4 is merely exemplary in nature, and the rods 74 may be arranged in various configurations along the two rods 72. For example, in another embodiment, the rods 74 may each be spaced apart from each other by different distances, or may not extend along the entire length L of the two rods 72. The arrangement of the rods 74 depends on the particular position of each of the frames 22.

Referring to fig. 2 and 3, a plurality of support members 28 are fixedly attached to the base 20. In the illustrated embodiment, each support member 28 defines a main body 80 and a plurality of projections 82 that extend upwardly and away from the main body 80 of the support member 28. Each support member 28 is releasably coupled to a corresponding one of the frames 22 by a fastening system 78. The fastening system 78 includes a plurality of mechanical fasteners 59. In the exemplary embodiment shown, the mechanical fasteners 59 are bolts. Specifically, each protrusion 82 of the support member 28 defines a hole 76, wherein the hole 76 is shaped to receive a corresponding portion of the fastener 59 (i.e., the shank of the bolt) of the fastening system 78. Each frame 22 also defines an aperture 77 corresponding to the aperture 76 of the support member 28. The aperture 77 is also shaped to receive one of the fasteners 59. Although the figures illustrate a fastening system 78 that includes a bolt, any other method may be used to releasably couple the lever 74 to the support member 28, such as, for example, a spring pin or dovetail fastener.

Fig. 5 is another view of one of the rotating assemblies 60 of the tool assembly 10. Referring to fig. 4 and 5, the rotation assembly 60 includes a shaft 64, a pillow block bearing 68, a selector plate 86, and an indexing mechanism 88. In the exemplary embodiment shown, the selector plate 86 includes a substantially semi-circular profile. The selector plate 86 defines a plurality of circumferentially spaced, uniformly shaped apertures 90. The aperture 90 may be disposed along a side surface 92 defined by the selector plate 86. The indexing mechanism 88 includes a rod or pin 94 attached to the leg 52 of the base 20. The pin 94 is shaped to correspond with the aperture 90 defined by the selector plate 86.

As shown in fig. 4, the shaft 64 is rotatably connected to the base 20. Specifically, the shaft 64 is rotatably connected to the second end portion 56 of the leg 52 through the aperture 62. The shaft 64 rotates about the axis of rotation a to relatively position the panel 24 in a particular angular position. A particular angular position of the panel 24 is measured relative to the axis of rotation a of the shaft 64. Specifically, referring to fig. 1 and 4-5, an operator may exert a force on the base 20 at one of the two rods 72. When a force is applied to the substrate 20, the shaft 64 rotates within the pillow block bearing 68 about its axis of rotation a in either a clockwise or counterclockwise direction. As the shaft 64 rotates about the axis of rotation a, the lever 74, the support member 28, the frame 22, and the panel 24 (fig. 1) rotate with the shaft 64. Once the operator has rotated the face plate 24 into a particular angular position, the operator may then insert the pin 94 through one of the holes 90 of the selector plate 86. Once the pin 94 is received by one of the holes of the selector plate 86, the panel 24 is secured in a particular angular position. In the non-limiting embodiment as shown in the figures, the range of rotation of the panel 24 is about ninety degrees. However, in another embodiment, the panel 24 may include a range of rotation of three hundred and sixty degrees. Although the embodiment describes the rotating assembly 60 as a mechanical device that is manually driven by an operator, in another embodiment, the rotating assembly 60 is instead electronically driven. Specifically, the shaft 64 of the rotating assembly 60 is rotated about the axis of rotation a by a rotary actuator or servomotor (not shown in the figures).

Referring to fig. 3-5, in one embodiment, the tool assembly 10 includes a plurality of fiducial targets 100. In the illustrated embodiment, the shape of the fiducial target 100 is substantially spherical. The fiducial target 100 specifies a point relative to the tool assembly 10 to establish a fiducial. In the illustrated embodiment, three fiducial targets 100 are provided to define a plane. When the tool assembly 10 is placed within a machine vision system (not shown), the three reference targets 100 define a plane. Machine vision systems refer to techniques for providing imaging-based automated inspection and analysis for applications such as, but not limited to, automated inspection, process control, or robotic guidance.

Referring now to fig. 1 and 2, the vacuum cups 36 of the securing system 38 provide a suction force configured to releasably couple the panels 24 against the upper surface 34 of each of the frames 22. The vacuum cup 36 is fluidly connected to a vacuum generating device (not shown), such as, for example, a vacuum pump. In one embodiment, the vacuum generating device provides a suction force between the inner surface 102 of each vacuum cup 36 and the tool side surface 32 of the panel 24. However, in another approach, the suction created by pressing the vacuum cup 36 against the tool side surface 32 of the panel is sufficient to hold the panel 24 to the tool assembly 10. In other words, in some cases, the suction force may be generated without an external vacuum generating device. If suction is provided without a vacuum generating device, a check valve is provided so that there is no loss of suction. As shown in fig. 2, the vacuum cups 36 are arranged in a plurality of rows R, with each row R of vacuum cups 36 being supported by one of the frames 22. The vacuum cups 36 of each row R are fluidly connected to each other and to a vacuum generating device. For example, in one embodiment, a conduit, such as a pipe (not shown), is used to fluidly connect the row R of vacuum cups 36 with the vacuum generating device. In another embodiment, a channel (not visible in FIG. 2) within each frame 22 is used to fluidly connect the vacuum cup 36 with the vacuum generating device.

Fig. 8 shows the valve 104 connected at the rear surface 106 of one of the frames 22. Although a single valve 104 is shown in fig. 8, each frame 22 includes a corresponding valve 104. Referring to fig. 2 and 8, the tool assembly 10 includes a plurality of valves 104, wherein each of the valves 104 is fluidly connected to a corresponding row R of vacuum cups 36. Vacuum enters the valve 104 through the opening 110, passes through the valve 104, and enters a conduit or channel (not visible in FIG. 2) that is fluidly connected with the row R of vacuum cups 36. Each valve 104 may thus be adjusted to provide different levels of suction to releasably secure panel 24 against upper surface 34 of corresponding frame 22. For example, in one approach, a first row R1 of vacuum cups 36 is provided with a first level of vacuum, and a second row R2 of vacuum cups 36 positioned adjacent to the first row R1 is provided with a second level of vacuum. In one embodiment, vacuum is supplied to the first row R1 of vacuum cups 36, but not to the second row R2 of vacuum cups 36.

Referring now to fig. 1 and 2, the suction provided by the vacuum cup 36 is based at least in part on the thickness of the panel 24. Specifically, the suction force is sufficient to secure the panel 24 against the upper surface 34 of the frame 22. A tool side surface 32 of the face plate 24 abuts an upper surface 34 of each frame 22. In one embodiment, the panel 24 may be flexible such that the panel 24 is actually elastically deformed by suction into the contour defined by the upper surface 34 of the frame 22. However, in an alternative embodiment, the panel 24 is relatively stiff and the suction force cannot elastically deform the panel 24.

In the exemplary embodiment as shown in fig. 2, the upper surfaces 34 of the frames 22 each define a substantially arcuate or curved profile. However, the upper surface 34 of the frame 22 may include any number of contours. Further, fig. 2 shows each frame 22 having a substantially identical upper surface 34. Thus, the panel 24 also includes a substantially uniform cross-section when viewed along one of the sides 30 of the panel 24. However, in another embodiment, the panel 24 includes a variable cross-sectional profile. That is, the cross-section of the panel 24 is variable when viewed along one of the sides 30. If the panel 24 includes a variable cross-section, the upper surface 34 of the frame 22 will vary to create a variable cross-sectional profile of the panel 24.

The suction provided by the vacuum cup 36 holds the faceplate 24 in place against the frame 22 even as the shaft 64 and faceplate 24 rotate about the axis of rotation a (fig. 4). However, the suction force is not sufficient to elastically deform the panel 24 around the area where the vacuum cup 36 applies the vacuum. For example, in the embodiment shown in fig. 1-2, the suction provided by the vacuum cup 36 is insufficient to elastically deform the panel 24 such that the tool surface 26 includes a series of rounded indentations or dimples where the vacuum cup 36 contacts the tool side surface 32 of the panel 24. In one exemplary embodiment, the thickness T of the panel 24 is in the range of about 0.006 inches to about 0.022 inches (0.1524 millimeters to 0.5588 millimeters) and the amount of vacuum applied is in the range of about 0 to about 30 inches of mercury (0 to 1.00263 atm).

Referring to fig. 1-3, in one embodiment, the tool assembly 10 includes a plurality of stops 120. The stop 120 is a holding device that holds the panel 24 in place if there is a loss of vacuum so that the vacuum cup 36 can no longer hold a suction force sufficient to secure the panel 24 against the frame 22. As shown in fig. 1, two stops 120 may be positioned on rear surfaces 122 of two different frames 22, with edges 124 of panels 24 abutting stops 120. Thus, if the amount of vacuum provided to the vacuum cup 36 is lost or reduced, the stop 120 prevents the panel 24 from sliding off of the upper surface 34 (FIG. 2) of the frame 22. Referring to fig. 2 and 5, one or more stops 120 may also be positioned on both frames 22 on opposite sides 44 of the tool assembly 10. Specifically, the stops 120 may be positioned on the outermost surfaces 130 of the two frames 22 on the opposite sides 30.

In addition to holding the faceplate 24 during loss of vacuum, the stop 120 also serves as a fixed reference point for Computer Numerical Control (CNC) programming if the tool assembly 10 is placed within an automatic machine tool. For example, the stops 120 and the fiducial targets 100 are used to orient the tool assembly 10 and the panel 24 relative to the machine and/or facility coordinate system. Referring now to fig. 4, in some cases, the shaft 64 of the rotating assembly 60 is attached to a servo motor (not shown) and electronically rotates about its axis. The servo motor is synchronized with the automated machine tool. In one approach, the external machine may be synchronized with the rotation of the panel 24 about its axis of rotation a. With this arrangement, operations such as painting, drilling and machining may be performed on the face plate 24 supported by the tool assembly 10.

Fig. 6 is an alternative embodiment of the disclosed tool assembly 10, wherein the securing system 38 includes a manifold 200. As shown in fig. 6, the manifolds 200 are each disposed along the upper surface 34 of one of the frames 22. Although fig. 6 shows the manifold 200 disposed along the upper surface 34 of each frame 22, this embodiment is exemplary in nature, and the manifold 200 may be disposed along only a portion of the upper surface 34 of the frame 22. The manifolds 200 each include a corresponding gasket 202 received within a groove (not visible in fig. 6) located around an outer perimeter 204 of the upper surface 34 of each frame 22. Accordingly, the gasket 202 extends around the outer perimeter 204 of the upper surface 34 of one of the frames 22 to define one of the manifolds 200. The gasket 202 is a shaped elastomeric piece for sealing the upper surface 34 of the frame 22 to the tool side surface 32 (fig. 7) of the face plate 24.

Fig. 8 is an illustration of the valve 104 connected to the rear surface 106 of one of the frames 22, and fig. 9 is a cross-sectional view of the frame 22 shown in fig. 8. Referring now to fig. 6-8, vacuum enters the valve 104 through the opening 110, passes through the valve 104, and enters the channel 220 (fig. 9) within the frame 22. The channel 220 terminates at an opening 222 (see fig. 9) located along the upper surface 34 of the frame 22. The passage 220 fluidly connects one of the valves 104 to a corresponding one of the manifolds 200. Similar to the embodiment shown in fig. 1-5, each valve 104 is therefore adjusted to provide a different level of suction within each manifold 200. However, unlike the above-described embodiments that include a vacuum cup, an external vacuum generating device is required to provide a suction force to releasably couple the panels 24.

Once the vacuum generating device (not shown) is activated to generate the vacuum, the tool side surface 32 of the panel 24 (fig. 7) contacts the upper surface 34 of the frame 22. In other words, the vacuum within the manifold 200 is sufficient to enable the tool side surface 32 of the faceplate 24 to be flush with the upper surface 34 of the frame 22. Thus, the manifold 200 provides a suction force configured to releasably couple the panels 24 against the upper surface 34 of each of the frames 22.

Fig. 10 shows an exemplary process flow diagram illustrating a method 300 for supporting a panel 24 with the tool assembly 10. Referring now to fig. 1-3 and 10, the method 300 begins at block 302. In block 302, the method 300 includes fixedly attaching a plurality of support members 28 to the base 20. The method 300 then proceeds to block 304.

In block 304, the method 300 includes releasably coupling each support member 28 to a corresponding one of the frames 22 via the fastening system 78. As shown in fig. 2, the plurality of frames 22 each define a corresponding upper surface 34. The method 300 then proceeds to block 306.

In block 306, the method 300 includes releasably coupling the panel 24 to the plurality of frames 22 by providing a suction force by the securing system 38. Specifically, the suction force is configured to releasably secure the panel 24 against the upper surface 34 of the plurality of frames 22. The securing system 38 includes a plurality of vacuum cups 36 or a plurality of manifolds 200 each disposed along the upper surface 34 of one of the frames 22. Specifically, in the embodiment shown in fig. 1-5, the securing system 38 includes a vacuum cup 36. Alternatively, in the embodiment as shown in fig. 6-9, the fixation system 38 includes a manifold 200. The method 300 then terminates.

Referring generally to the drawings, the technical effects and benefits of the disclosed tool assembly include modularity, increased flexibility, and significant cost savings when compared to conventional tools. Conventional tools typically include a panel fixedly attached to a frame. Instead, the disclosed tool assembly includes a securing system for providing a suction force to releasably couple the panel against the upper surface of the frame, thereby allowing the panel to be removed and replaced with another type of panel. Thus, the tool surface of the faceplate is interchangeable. Further, the frame is also releasably secured to the frame. Thus, the frame of the tool assembly remains unchanged, only the frame and the face plate need to be replaced to make another part. The disclosed tool assembly may significantly reduce costs when compared to conventional tool techniques, as only the frame that needs repair or replacement may be removed from the tool assembly. The disclosed tool assembly may also require less storage space when compared to current tools, as the frame may be removed and stored on a tray rack, and another set of frames may be mounted to the base of the tool assembly. Finally, the tool assembly can be used in a variety of different applications such as, for example, machining, development, drilling/mating, assembly, lamination, sealing, and automatic indexer/shaft.

Further, the present disclosure includes embodiments according to the following clauses:

clause 1. a tool assembly (10) for use with a face plate (24) defining a tool side surface (32), and the tool side surface (32) defines a contour, the tool assembly comprising: a substrate (20); a plurality of support members (28) fixedly attached to the base (20); a plurality of frames (22), each defining a corresponding upper surface (34), wherein each of the support members (28) is releasably coupled to a corresponding one of the frames (22) by a fastening system (78), wherein the plurality of frames (22) are configured to be releasably coupled to the panel (24), and wherein the upper surfaces (34) of the frames (22) are each shaped to correspond to a portion of a contour of the tool side surface (32) of the panel (24); and a securing system (38) configured to provide a suction force that releasably secures the panel (24) against the upper surface (34) of the frame (22).

Clause 2. a tool assembly (10) for use with a face plate (24) defining a tool side surface (32), and the tool side surface (32) defines a contour, the tool assembly (10) comprising: a substrate (20); a plurality of support members (28) fixedly attached to the base (20); a plurality of frames (22), each defining a corresponding upper surface (34), wherein each of the support members (28) is releasably coupled to a corresponding one of the frames (22) by a fastening system (78), the plurality of frames (22) being configured to be releasably coupled to the panel (24), and wherein the upper surfaces (34) of the frames (22) are each shaped to correspond to a portion of a contour of the tool side surface (32) of the panel (24); a securing system (38) configured to provide a suction force that releasably secures the panel (24) against the upper surface (34) of the frame (22); and a rotation assembly (60) including a shaft (64), the shaft (64) defining an axis of rotation (a) and being rotatably connected to the base (20), wherein the shaft (64) rotates about the axis of rotation to position the panel (24) into a particular angular position.

Clause 3. the tool assembly (10) according to clause 1 or 2, wherein the securing system (38) comprises a plurality of vacuum cups (36) arranged in a plurality of rows (R).

Clause 4. the tool assembly (10) according to clause 3, wherein the vacuum cups (36) of the single row (R) are fluidly connected to each other.

Clause 5. the tool assembly (10) according to clause 4, further comprising a conduit fluidly connecting the vacuum cups (36) of each row (R) with the vacuum generating device.

Clause 6. the tool assembly (10) of clause 4, further comprising a channel within each frame (22) fluidly connecting the vacuum cup (36) and the vacuum generating device together.

Clause 7. the tool assembly (10) according to any one of clauses 3 to 6, comprising a plurality of valves (104), wherein each of the valves (104) is fluidly connected to a corresponding row (R) of vacuum cups (36).

Clause 8. the tool assembly (10) according to any of clauses 3 to 7, wherein a first row of vacuum cups (36) is provided with a first level of vacuum and a second row, positioned adjacent to the first row, is provided with a second level of vacuum.

Clause 9. the tool assembly (10) according to any one of clauses 3 to 8, wherein each row (R) of vacuum cups (36) is supported by one of the frames (22).

Clause 10. the tool assembly (10) according to any one of clauses 1 to 9, wherein the fastening system (78) comprises a plurality of mechanical fasteners (59).

Clause 11. the tool assembly (10) according to any one of clauses 1-10, wherein each of the support members (28) defines a body (80) and a plurality of projections (82) extending upwardly and away from the body (80).

Clause 12. the tool assembly (10) according to clause 11, wherein each of the protrusions (82) of the support member (28) defines an aperture (76), wherein the apertures (76) are shaped to receive a corresponding fastener (59) of a fastening system (78).

Clause 13. the tool assembly (10) according to any one of

clauses

1, 2 or 10 to 12, wherein the securing system (38) includes a plurality of manifolds (200) each disposed along the upper surface (34) of one of the frames (22).

Clause 14. the tool assembly (10) according to clause 13, wherein the manifolds (200) each include a corresponding gasket (202), and wherein the gaskets (202) extend around an outer perimeter (204) of the upper surface (34) of one of the frames (22) to define one of the manifolds (200).

Clause 15. the tool assembly (10) according to clause 13 or 14, wherein each frame (22) includes a channel (220) therein, the channel (220) terminating at an opening (222) located along the upper surface (34) of the frame (22) and fluidly connecting the valve (104) to a corresponding one of the manifolds (200).

Clause 16. the tool assembly (10) of clause 7 or 15, wherein each frame (22) includes a corresponding valve (104).

Clause 17. the tool assembly (10) according to any one of clauses 1 or 3 to 16, including a rotating assembly (60) having a shaft (64), wherein the shaft (64) is rotatably connected to the base (20).

Clause 18. the tool assembly (10) according to clause 17, wherein the shaft (64) defines an axis of rotation (a), and wherein the shaft (64) rotates about the axis of rotation (a) to position the face plate (24) in a particular angular position.

Clause 19. the tool assembly (10) according to any of clauses 2, 17 or 18, wherein the rotating assembly (60) further comprises: a selector plate (86) including a plurality of apertures (90) spaced along the selector plate (86); and an indexing mechanism (88) including pins (94) shaped to correspond with the plurality of holes (90) of the selector plate (86).

Clause 20. the tool assembly (10) according to clause 19, wherein a pin (94) is inserted into one of the holes (90) of the selector plate (86) to fix the face plate (24) at a particular angular position.

Clause 21. the tool assembly (10) according to any one of clauses 1-20, wherein the tool side surface (32) of the face plate (24) abuts the upper surface (34) of each frame (22).

Clause 22. the tool assembly (10) according to any one of clauses 1 to 21, wherein the base (20) comprises a pair of rods (72) and a plurality of rods (74) mounted along the pair of rods (72), the plurality of rods (74) being perpendicular to the pair of rods (72).

Clause 23. the tool assembly (10) of clause 22, wherein the support member (28) is releasably coupled to the plurality of rods (74).

Clause 24. the tool assembly (10) of clause 22 or 23, wherein the rod (74), the support member (28), the frame (22) and the shaft (64) rotate together.

Clause 25. the tool assembly (10) according to any one of clauses 1-24, further comprising a plurality of stops (120) configured to prevent the panel (24) from sliding off the upper surface (34) of the frame (22).

Clause 26. a method for supporting a panel (24) by a tool assembly (10), the method comprising: fixedly attaching (302) a plurality of support members (28) to a substrate (20); releasably coupling each of the support members (28) to a corresponding one (304) of the plurality of frames (22) by a fastening system (78), wherein the frames (22) each define a corresponding upper surface (34); and releasably coupling (306) the panel (24) to the upper surface (34) of the frame (22) by providing a suction force, wherein the suction force is provided by the securing system (38).

Clause 27. the method of clause 26, further comprising disposing a plurality of vacuum cups (36) or a plurality of manifolds (200) along the upper surface (34) of one of the frames (22).

Clause 28. the method of clause 26 or 27, wherein the tool assembly (10) includes a plurality of valves (104), wherein each of the valves (104) is fluidly connected to a corresponding row (R) of vacuum cups (36) or a corresponding manifold (200), the method further comprising: each valve (104) is adjusted to provide a different level of suction to releasably secure the panel (24) against the upper surface (34) of the corresponding frame (22).

Clause 29. the method of clause 28, wherein adjusting each valve (104) comprises: providing a first level of vacuum to a first row (R) of vacuum cups (36) or a first manifold (200); and providing a second level of vacuum to a second row (R) of vacuum cups (36), preferably wherein the first row (R) is adjacent to the second row (R) or the second manifold (200).

Clause 30. the method of any of clauses 26-29, further comprising operating a suction system (38) to apply an amount of suction to the panel (24) based at least on the thickness of the panel (24).

Clause 31. the method according to any one of claims 26 to 30, wherein the tool assembly (10) comprises a rotating assembly (60) that: a shaft (64) including a shaft rotatably coupled to the base (20); a selector plate (86) including a plurality of apertures (90) spaced along the selector plate (86); and an indexing mechanism (88) including pins (94) shaped to correspond with the plurality of holes (90) of the selector plate (86), wherein the method further comprises: the shaft (64) is rotated about an axis of rotation (a) to position the panel (24) in a particular angular position, the shaft (64) defining the axis of rotation (a).

Clause 32. the method of clause 31, wherein the rotating assembly (60) includes a selector plate (86) including a plurality of apertures (90) spaced apart along the selector plate (86), and an indexing mechanism (88) including pins (94) shaped to correspond with the plurality of apertures (90) of the selector plate (86), wherein the method further comprises: a pin (94) is inserted into one of the holes (90) of the selector plate (86) to secure the face plate (24) in a particular angular position.

While the forms of apparatus and methods described herein constitute preferred aspects of the present disclosure, it is to be understood that the present disclosure is not limited to these precise forms of apparatus and methods, and that changes may be made therein without departing from the scope of the present disclosure.

Claims

1. A tool assembly (10) for use with a face plate (24) defining a tool side surface (32), and the tool side surface (32) defines a profile, the tool assembly comprising:

a substrate (20);

a plurality of support members (28) fixedly attached to the base (20), wherein the base (20) includes a pair of rods (72) oriented perpendicular to the plurality of support members (28) and a plurality of rods (74) mounted along the pair of rods (72), the plurality of rods (74) being perpendicular to the pair of rods (72), wherein the support members (28) are releasably coupled to the plurality of rods (74);

a plurality of frames (22), each defining a corresponding upper surface (34), wherein each of the support members (28) is releasably coupled to a corresponding one of the frames (22) by a fastening system (78), wherein the plurality of frames (22) are configured to be releasably coupled to the panel (24), and wherein the upper surfaces (34) of the frames (22) are each shaped to correspond with a portion of the contour of the tool side surface (32) of the panel (24), and wherein the plurality of rods (74) are arranged in various configurations along the pair of rods (72), the arrangement of the plurality of rods (74) being dependent on the particular position of each of the plurality of frames (22); and

a securing system (38) configured to provide a suction force releasably securing the panel (24) against the upper surface (34) of the frame (22).

2. The tool assembly (10) according to claim 1, wherein the securing system (38) comprises a plurality of vacuum cups (36) arranged in a plurality of rows (R), wherein the vacuum cups (36) of a single row (R) are fluidly connected to each other.

3. The tool assembly (10) according to claim 2, further comprising a plurality of valves (104), wherein each of the valves (104) is fluidly connected to a corresponding row (R) of the vacuum cups (36).

4. The tool assembly (10) according to claim 2, wherein a first row of the vacuum cups (36) is provided with a first level of vacuum and a second row located adjacent to the first row is provided with a second level of vacuum.

5. The tool assembly (10) according to claim 1, wherein the fastening system (78) comprises a plurality of mechanical fasteners (59).

6. The tool assembly (10) according to claim 1, wherein each of the support members (28) defines a body (80) and a plurality of projections (82) extending upwardly and away from the body (80), wherein each of the projections (82) of the support members (28) defines an aperture (76), wherein the apertures (76) are shaped to receive corresponding fasteners (59) of the fastening system (78).

7. The tool assembly (10) according to claim 1, wherein the securing system (38) includes a plurality of manifolds (200) each disposed along the upper surface (34) of one of the frames (22), wherein the manifolds each include a corresponding gasket (202), and wherein the gaskets (202) extend around an outer perimeter (204) of the upper surface (34) of one of the frames (22) to define one of the manifolds (200).

8. The tool assembly (10) according to claim 1, further comprising a rotation assembly (60) including a shaft (64), wherein the shaft (64) is rotatably connected to the base (20), wherein the shaft (64) defines an axis of rotation (a), and wherein the shaft (64) rotates about the axis of rotation (a) to position the face plate (24) in a particular angular position.

9. The tool assembly (10) according to claim 1, wherein the tool side surface (32) of the face plate (24) abuts the upper surface (34) of each frame (22).

10. The tool assembly (10) according to claim 8, wherein the rotation assembly (60) further comprises:

a selector plate (86) including a plurality of apertures (90) spaced along the selector plate (86); and

an indexing mechanism (88) including pins (94) shaped to correspond with the plurality of holes (90) of the selector plate (86).

11. A tool assembly (10) for use with a face plate (24) defining a tool side surface (32), and the tool side surface (32) defines a profile, the tool assembly (10) comprising:

a substrate (20);

a plurality of frames (22), each defining a corresponding upper surface (34), wherein each of the support members (28) is releasably coupled to a corresponding one of the frames (22) by a fastening system (78), the plurality of frames (22) configured to be releasably coupled to the panel (24), and wherein the upper surfaces (34) of the frames (22) are each shaped to correspond with a portion of the contour of the tool side surface (32) of the panel (24), and wherein the plurality of rods (74) are arranged in various configurations along the pair of rods (72), the arrangement of the plurality of rods (74) being dependent on the particular position of each of the plurality of frames (22); and

a securing system (38) configured to provide a suction force releasably securing the panel (24) against the upper surface (34) of the frame (22); and

a rotation assembly (60) comprising a shaft (64), the shaft (64) defining an axis of rotation (A) and being rotatably connected to the base (20), wherein the shaft (64) rotates about the axis of rotation to position the panel (24) into a particular angular position.

12. The tool assembly (10) according to claim 11, wherein the securing system (38) includes a plurality of vacuum cups (36) arranged in a plurality of rows (R).

13. Tool assembly (10) according to claim 12, wherein the vacuum cups (36) of each row (R) are fluidly connected to each other.

14. The tool assembly (10) according to claim 11, wherein the securing system (38) includes a plurality of manifolds (200) each disposed along the upper surface (34) of one of the frames (22).

15. The tool assembly (10) according to claim 14, wherein the manifolds (200) each include a corresponding gasket (202), and wherein the gaskets (202) extend around an outer perimeter (204) of the upper surface (34) of one of the frames (22) to define one of the manifolds (200).

16. A method for supporting a panel (24) by a tool assembly (10), the method comprising:

step (302): fixedly attaching a plurality of support members (28) to a base (20), wherein the base (20) includes a pair of rods (72) oriented perpendicular to the plurality of support members (28) and a plurality of rods (74) mounted along the pair of rods (72), the plurality of rods (74) being perpendicular to the pair of rods (72), wherein the support members (28) are releasably coupled to the plurality of rods (74);

step (304): releasably coupling each of the support members (28) to a corresponding one of a plurality of frames (22) by a fastening system (78), wherein the frames (22) each define a corresponding upper surface (34), and wherein the plurality of rods (74) are arranged in various configurations along the pair of rods (72), the arrangement of the plurality of rods (74) being dependent on the specific location of each of the plurality of frames (22); and

step (306): releasably coupling the panel (24) to the upper surface (34) of the frame (22) by providing a suction force, wherein the suction force is provided by a securing system (38).

17. The method of claim 16, wherein the tool assembly (10) includes a plurality of valves (104), wherein each of the valves (104) is fluidly connected to a corresponding row (R) of vacuum cups (36) or a corresponding manifold (200), the method further comprising:

each valve (104) is adjusted to provide a different level of suction to releasably secure the panel (24) against the upper surface (34) of the corresponding frame (22).

18. The method of claim 17, wherein adjusting each valve (104) comprises:

providing a first level of vacuum to a first row (R) of vacuum cups (36) or a first manifold (200); and

providing a second level of vacuum to a second row (R) of vacuum cups (36), wherein the first row (R) is adjacent to the second row (R) or a second manifold (200).

19. The method according to any one of claims 17 to 18, wherein the tool assembly (10) comprises a rotating assembly (60) comprising: a shaft (64) rotatably coupled to the base (20); a selector plate (86) including a plurality of apertures (90) spaced along the selector plate (86); and an indexing mechanism (88) including pins (94) shaped to correspond with the plurality of holes (90) of the selector plate (86), wherein the method further comprises:

rotating the shaft (64) about an axis of rotation (A) to position the panel (24) in a particular angular position, the shaft (64) defining the axis of rotation (A); and

inserting the pin (94) into one of the holes (90) of the selector plate (86) to fix the face plate (24) at the particular angular position.

20. The method of claim 16, wherein the securing system (38) includes a plurality of vacuum cups (36) or a plurality of manifolds (200) each disposed along the upper surface (34) of one of the frames (22).